CHAPTER 1

INTRODUCTION
1.1.1 HEAT EXCHANGER

A heat exchanger transfers energy from one fluid to another across a solid surface by convection
and conduction. Heat exchangers are used in power plants, nuclear reactors, refrigeration and air
conditioning systems, automotive industries, heat recovery systems, chemical processing, and
food industries. The design of a new heat exchanger (HE) is referred to the sizing problem,
means it includes construction type, flow arrangement, tube and shell material, and physical size
which has to meet the specified heat transfer and pressure drop rating of existing heat exchanger.
We are going to simulate the results for present material of shell and tube heat exchanger and
change the material, then compare the results of both and study which is best. Shell and tube heat
exchanger consist bundle of tubes enclosed with in cylindrical shell one fluid pass through the
tubes and second fluid flows between the tube and shells. The basic components of a shell and
tube heat exchangers are tubes, tube sheets, shell and shell-side nozzles, tube side channels and
nozzles, channel covers, pass divider, baffles etc. Most commonly used STHE have large heat
transfer surface area-to-volume ratios to provide high heat transfer efficiency in comparison with
others. They are mechanically rugged enough to withstand the fabrication stresses and normal
operating conditions. They can be easily cleaned and the failure parts like gaskets and tubes can
be easily replaced. They offer greater flexibility of mechanical features to withstand any service
requirement. They are manufactured easily for a large variety of sizes and flow configurations.
They can operate at high pressures and high temperature. They can be employed for processes
which require large quantities of fluid to be heated or cooled. A heat exchanger is a device,
which transfer internal thermal energy between two or more fluids at different temperature.
Without this essential piece of equipment most industrial process would be impossible. Heat
exchangers are widely used in refrigeration air conditioning, and chemical plants. They can be
employed in various uses, for instance, to effectively transmit heat from one fluid to the other.
Shell-and-tube heat exchangers (STHXs) are widely applied in various industrial fields such as
petroleum refining, power generation and chemical process, etc. Tremendous efforts have been
made to improve the performances on the tube side.In this project experimental performance is
done on the fixed designed STHX and calculate the heat transfer coefficient and effectiveness.
Validation is to be carried out using which gives the result comparison with that of experimental
result.

fig.1.1:-Heat Exchanger

1.1.2 CLASSIFICATION OF HEAT EXCHANGER

1) Based on construction
a) Double pipe
b) Shell and Tube
c) Coiled type
2) Based on transfer process
a) Direct contact
b) Indirect contact
3) Based on flow arrangement
 a) Single pass
b) Multi pass
4) Based on phase of liquid
a) Gaseous
b) Liquid

1.1.3 COMPONENTS OF HEAT EXCHANGER

1. Stationary channel head

2. Channel flange
3. Part partition plate
4. Tube sheet
5. Shell flange
6. Tube
7. Shell
8. Baffle
9. Stationary head bonnet
10. Tube fluid in
11. Tube fluid out ‘
12. Shell fluid in
13. Shell fluid out

1) Stationary channel head

Stationary channel head is required for shell-and-tube heat exchangers to contain the tube side
fluid and to provide the desired flow path. There are basically three types of channel head is
available represents by TEMA. The channel type is selected based on the application. Most
channels can be removed for access to the tubes. The channel type is selected based on the
application. Most channels can be removed for access to the tubes. The channel type is selected
based on the application. Most channels can be removed for access to the tubes. The channel
type is selected based on the application. Most channels can be removed for access to the
tubes. The most commonly used channel type is the bonnet. It is used for services which do not
require frequent removal of the channel for inspection or cleaning. The removable cover channel
can be either flanged or welded to the tubesheet.
2) Channel flange

Channel flange is used to tight up the stationary channel head and shell flange by using welding
or nut bolt.

3) Part partition plate

Part partition plate is provided into the stationary head channel at the middle. This is used to
separate the inlet and outlet tubes of heat exchanger. This prevents from the leakage of fluid
inside stationary head channel.

4) Tube sheet

Tube sheets are plates or forgings drilled to provide holes through which tubes are
inserted. Tubes are appropriately secured to the tubesheet so that the fluid on the shell side is
prevented from mixing with the fluid on the tube side. Holes are drilled in the tubesheet
normally in either of two patterns, triangular or square.

5) Shell flange

Shell flange is provided at the end of shell with higher diameter compare to shell diameter and it
is connected with channel flange.

6) Tube

Tubing may be seamless or welded. Seamless tubing is produced in an extrusion process;

welded tubing is produced by rolling a strip into a cylinder and welding the seam. Welded
tubing is usually more economical.

7) Shell

Shell is the container for the shell fluid and the tube bundle is placed inside the shell. It acts as a
protector of tubes bundle and baffles

8) Baffle

Baffles serve three functions support the tube, maintain the tube spacing, direct the flow of fluid
in the desired pattern through the shell side.

9) Stationary head bonnet

Stationary head bonnet is used at the end of the shell to protect the tubes and shell fluid.
10) Tube fluid in

The fluid which is entered into the tube is known as tube fluid in. This fluid flows through the
tube.

11) Tube fluid out

The fluid which flows through the tube and exchanges heat throughout the flowing then finally it
comes out of the tube which is known as tube fluid out.

12) Shell fluid in

The fluid which is passed into the shell to absorb the heat of tube fluid is called shell fluid in.
Usually the water is used as a shell fluid in because it has high value of absorbing a heat.

13) Shell fluid out

The hot fluid comes out of shell which is called shell fluid out.

1.1.4 REQUIRED PROPERTIES OF HEAT EXCHANGER

1. It should have a high heat transfer coefficient particularly in tube material.

2. Thermal expansion coefficient to be low as much as possible of those materials which are
used as tube sheet, tube support and shell to provide thermal expansion cycling.
3. The heat exchanger should be designed in such a structure so it can give the desired
working efficiency at different ambient temperature.
4.
.